Tensioned gun barrel liners, and methods and apparatus for tensioning gun barrel liners are disclosed. Tensioned gun barrels have been shown to have superior performance. The apparatus allows for axial strain to be imparted into the gun barrel using mechanical means while other embodiments utilize thermal expansion of the material such as metal that is used for the gun barrel liner to introduce the strain and maintain it using other mechanical means or applied material such as composites.

Tensioned gun barrel liners, and methods and apparatus for tensioning gun barrel liners are disclosed. Tensioned gun barrels have been shown to have superior performance. The apparatus allows for axial strain to be imparted into the gun barrel using mechanical means while other embodiments utilize thermal expansion of the material such as metal that is used for the gun barrel liner to introduce the strain and maintain it using other mechanical means or applied material such as composites.

A modular barrel system for firearm includes a first barrel segment and a second barrel segment. Each barrel segment comprises a tubular member having an axial bore, a proximal end, and a distal end. The proximal end of the first barrel segment has a first threaded element for removably attaching the first barrel segment to a firearm. The distal end of the first barrel segment has a second threaded element and the proximal end of the second barrel segment has a third threaded element which is complementary with the second threaded element, the third threaded element for removably attaching the second barrel segment to the first barrel segment. In a further aspect, method for the manufacture of a modular barrel system are provided.

A conversion kit (1) for converting a firearm to fire a plurality of different types of non-lethal training ammunition comprises a single barrel (2) and a plurality of interchangeable barrel liners (3) which can be used in place of each other. The barrel (2) defines a bore (4) which receives one of the barrel liners (3) for firing non-lethal training ammunition and each barrel liner (3) is specific for a type of non-lethal training ammunition.

A conversion kit (1) for converting a firearm to fire a plurality of different types of non-lethal training ammunition comprises a single barrel (2) and a plurality of interchangeable barrel liners (3) which can be used in place of each other. The barrel (2) defines a bore (4) which receives one of the barrel liners (3) for firing non-lethal training ammunition and each barrel liner (3) is specific for a type of non-lethal training ammunition.

A projectile launch system includes a longitudinally extending launch tube having an inner bore formed therethrough. The launch tube having a metal liner and a composite overwrap, and a firing pin aperture formed in the longitudinally extending launch tube. A firing pin sleeve can be coupled with the metal liner and extend through at least a portion of the firing pin aperture, and a receiver including a launch control system.

Methods of manufacturing metal, metal-matrix, metal-metal-matrix composite weapon barrels offer barrels with improved thermal performance and rigidity with no, minimal or negative weight increase. A barrel may include a barrel core surrounded by a lightweight, thermally conductive sleeve made from metal, metal-matrix composite (MMC) materials, also referred to as metal-matrix material. The barrel core and barrel sleeve may include aligning features to prevent separation and movement of the sleeve along the core. The disclosed methods provide for material combinations and part designs that prevent separation of their parts over the life of the weapon barrel and allow the barrel to perform at high cadence over the whole temperature range the barrel is used.

Methods of manufacturing metal, metal-matrix, metal-metal-matrix composite weapon barrels offer barrels with improved thermal performance and rigidity with no, minimal or negative weight increase. A barrel may include a barrel core surrounded by a lightweight, thermally conductive sleeve made from metal, metal-matrix composite (MMC) materials, also referred to as metal-matrix material. The barrel core and barrel sleeve may include aligning features to prevent separation and movement of the sleeve along the core. The disclosed methods provide for material combinations and part designs that prevent separation of their parts over the life of the weapon barrel and allow the barrel to perform at high cadence over the whole temperature range the barrel is used.

A guide system for use in electro-processing a bore of a gun barrel includes a non-conductive external bore guide and a non-conductive internal bore guide. The external bore guide is an adapter that is configured to removably engage the outside of the gun barrel and includes a conduit formed therein. The conduit is disposed such that it is axially aligned with a bore of the gun barrel when the external bore guide is engaged with the gun barrel. The internal bore guide is elongated and includes an axial recess that is sized to seat an electro-processing electrode (an anode). A method for uniformly plating the bore includes moving an anode through the gun barrel at one or more rate(s) of travel to uniformly plate the bore is also disclosed. The plating is sufficiently uniform to conform to military specifications. The systems, methods, support structures, etc. described herein are particularly well-suited to plating small-bore gun barrels.

A guide system for use in electro-processing a bore of a gun barrel includes a non-conductive external bore guide and a non-conductive internal bore guide. The external bore guide is an adapter that is configured to removably engage the outside of the gun barrel and includes a conduit formed therein. The conduit is disposed such that it is axially aligned with a bore of the gun barrel when the external bore guide is engaged with the gun barrel. The internal bore guide is elongated and includes an axial recess that is sized to seat an electro-processing electrode (an anode). A method for uniformly plating the bore includes moving an anode through the gun barrel at one or more rate(s) of travel to uniformly plate the bore is also disclosed. The plating is sufficiently uniform to conform to military specifications. The systems, methods, support structures, etc. described herein are particularly well-suited to plating small-bore gun barrels.